Floor Panels and Flooring Systems for a Passenger Vehicle, and Methods for Installation

ABSTRACT

An example floor panel for a flooring system in a passenger vehicle includes a top sheet, a bottom sheet, a body situated between the top sheet and the bottom sheet, and an interlocking feature that extends outward from the body for slidably engaging an adjacent floor panel. An example flooring system in a passenger vehicle includes a first set of floor panels including panels rigidly attached to a structure of the passenger vehicle, and a second set of floor panels and each floor panel of the second set of floor panels has an interlocking feature for slidably engaging an adjacent floor panel and for enabling lateral relative motion to occur and restricting vertical relative motion between panels of the second set of floor panels and a respective adjacent floor panel.

FIELD

The present disclosure generally relates to floor panels, and moreparticularly to, interlocking floor panels that can enable relativemotion to occur between adjacent floor panels.

BACKGROUND

Cabin floors for commercial and military aircraft can typically includea structural sub-floor with a thin laminate covering and a top floorcovering sealed to the thin laminate covering. A moisture barrier tapecan be provided along seams of the sub-floor as well. Within thisexisting design, double back tape is laid down on the entire sub-floorarea, to which the rigid laminate sections are laid and sealed. Then, asecond layer of double back tape is laid over the laminate sections,followed by panels of the top floor covering. This technique describedabove for forming a floor can be a time consuming and difficult torepeat in a production environment. In addition, replacement or repairof a single floor structure panel can be difficult due to the panelsbeing firmly bonded to each other.

At least some known conventional flooring for use in buildings, such ashardwood or solid, hard flooring (e.g., tile or laminate) may not bepractical for use on an aircraft because the aircraft flooring describedabove is configured to withstand certain vertical loads (e.g., aboutthree times gravity) that hard flooring used in buildings does notexperience. Further, a sub-floor on an aircraft or other vehicle isconfigured to move (i.e., shift with respect to a structural componentand/or flex), which can make traditional hardwood or solid flooringimpractical. Additionally, hardwood flooring used in buildings can berelatively heavy, causing unnecessary extra weight on the aircraft.Also, during changes of altitude during a flight, air pockets inadhesives can expand and/or contract over time making a surface un-levelwhen the aircraft is at cruise altitude (e.g., lower pressure).Moreover, hardwood flooring for use in buildings generally does notabsorb noise as well as carpet, and spills can create a slip hazard onhard flooring types for use in buildings.

SUMMARY

In one example, a floor panel for a flooring system in an aircraft isdescribed. The floor panel comprises a top sheet, a bottom sheetopposite the top sheet, a body comprising a plurality of cells eachhaving a cavity therein and the body is situated between the top sheetand the bottom sheet, and an interlocking feature that extends outwardfrom the body for slidably engaging an adjacent floor panel. Theinterlocking feature is formed via an outward extension of the bottomsheet beyond the top sheet such that the top sheet is raised withrespect to the interlocking feature to create a seat configured forengaging the adjacent floor panel.

In another example, a flooring system in a passenger vehicle isdescribed. The flooring system comprises a first set of floor panelsincluding panels rigidly attached to a structure of the passengervehicle, and a second set of floor panels. Each floor panel of thesecond set of floor panels has an interlocking feature for slidablyengaging an adjacent floor panel, and the interlocking feature isconfigured to enable lateral relative motion to occur and restrictvertical relative motion between panels of the second set of floorpanels and a respective adjacent floor panel. The second set of floorpanels are positioned to define a space between a respective floor panelof the second set of floor panels and the respective adjacent floorpanel to enable the lateral relative motion to occur between panels ofthe second set of floor panels and the respective adjacent floor panel,and each floor panel of the second set of floor panels is positioned toengage at least one adjacent floor panel of the first set of floorpanels.

In another example, a method for installing a flooring system in apassenger vehicle is described. The method comprises attaching a firstset of floor panels to a structure of the passenger vehicle at locationsdistributed throughout an area of the passenger vehicle, and positioninga second set of floor panels such that each floor panel of the secondset of floor panels is positioned to engage at least one adjacent floorpanel of the first set of floor panels. Each floor panel of the secondset of floor panels has an interlocking feature for slidably engaging anadjacent floor panel, and the interlocking feature is configured toenable lateral relative motion to occur and restrict vertical relativemotion between panels of the second set of floor panels and a respectiveadjacent floor panel. The second set of floor panels are positioned todefine a space between a respective floor panel of the second set offloor panels and the respective adjacent floor panel to enable thelateral relative motion to occur between panels of the second set offloor panels and the respective adjacent floor panel; and filling thespace with a sealant or an elastomer insert.

Various examples of the system(s) and apparatus(es) described herein mayinclude any of the components, features, and functionalities of any ofthe other examples of the system(s) and apparatus(es) described hereinin any combination.

Various examples of the method(s) described herein may include any ofthe components, features, and functionalities of any of the otherexamples of the method(s) described herein in any combination.

The features, functions, and advantages that have been discussed can beachieved independently in various examples or may be combined in yetother examples further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE FIGURES

The novel features believed characteristic of the illustrative examplesare set forth in the appended claims. The illustrative examples,however, as well as a preferred mode of use, further objectives anddescriptions thereof, will best be understood by reference to thefollowing detailed description of an illustrative example of the presentdisclosure when read in conjunction with the accompanying drawings,wherein:

FIG. 1 is a top view of an example floor panel for a flooring system inan aircraft.

FIG. 2 is a top view of the floor panel of FIG. 1 showing a partialcross-section.

FIG. 3 is a bottom view of the floor panel of FIGS. 1 and 2 showinganother partial cross-section.

FIG. 4 is a transparent view of a portion of the floor panel of FIGS. 1to 3 to show an example of the plurality of cells.

FIG. 5 is a side view of the floor panel of FIGS. 1 to 4.

FIG. 6 is another side view of the floor panel of FIGS. 1 to 4 with asurface on the floor panel.

FIG. 7 is a side view of another example of another floor panel.

FIG. 8 is another top view of another example of the floor panel.

FIG. 9 illustrates an example flooring system in a passenger vehicle,such as an aircraft.

FIG. 10 illustrates a magnified view of a portion of the flooring systemof FIG. 9.

FIG. 11 is a side view of a portion of the flooring system of FIG. 9showing the floor panel interlocked with an adjacent floor panel.

FIG. 12 is another side view of a portion of the flooring system of FIG.9 showing the floor panel interlocked with an adjacent floor panel.

FIG. 13 is another side view of a portion of the flooring system of FIG.9 showing the floor panel interlocked with an adjacent floor panel.

FIG. 14 illustrates a schematic layout of the flooring system in aportion of a passenger vehicle, such as an aircraft.

FIG. 15 shows a flowchart of an example method for installing theflooring system in the aircraft.

FIG. 16 shows a flowchart of additional functions that may be used withor after implementation of the method in FIG. 15.

DETAILED DESCRIPTION

Disclosed examples will now be described more fully hereinafter withreference to the accompanying drawings, in which some, but not all ofthe disclosed examples are shown. Indeed, several different examples maybe described and should not be construed as limited to the examples setforth herein. Rather, these examples are described so that thisdisclosure will be thorough and complete and will fully convey the scopeof the disclosure to those skilled in the art.

Within examples herein, components for interior cabin of a passengervehicle, such as an aircraft, train, or ship, and specifically to floorcoverings for passenger vehicles, are described. There is a long feltneed for hardwood or solid, hard flooring on an aircraft, especially insome premier cabin areas. Thus, the embodiments described herein canprovide a look and feel of hardwood flooring on an aircraft, taking theabove and other factors into consideration. More specifically the floorstructure described herein can reduce installation time, provideincreased reliability and repeatability of installation, allow forimproved aesthetics, increased durability, and/or provide the ability toreplace individual panels.

Referring now to the figures, FIG. 1 is a top view of an example floorpanel 100 for a flooring system in an aircraft, according to an example.FIG. 2 is a top view of the floor panel 100 showing a partialcross-section. The floor panel 100 includes a top sheet 102, a bottomsheet 104 opposite the top sheet 102, and a body 106 situated betweenthe top sheet 102 and the bottom sheet 104. The floor panel 100 alsoincludes an interlocking feature 108 that extends outward from the body106 for slidably engaging an adjacent floor panel. The interlockingfeature 108 is formed via an outward extension 109 of the bottom sheet104 beyond the top sheet 102 such that the top sheet 102 is raised withrespect to the interlocking feature 108 to create a seat 110 configuredfor engaging the adjacent floor panel.

The body 106 comprises a plurality of cells 112 each having a cavitytherein, such as cavity 114. Further description of the body 106 isbelow with reference to FIG. 4.

The interlocking feature 108 is configured to enable the floor panel 100to slidably engage an adjacent floor panel during installation, as ismore fully described below. For example, the seat 110 is configured forengaging the adjacent floor panel 124, and the seat 110 includes theinterlocking feature 108 abutting the top sheet 102 at about a 90°angle. However, the interlocking feature 108 can abut the top sheet 102at any suitable angle that can enable the floor panel 100 to engage theadjacent floor panel 124.

Within examples, the top sheet 102, the bottom sheet 104, the body 106,and the interlocking feature 108 are a single piece construction. Thus,the floor panel 100 may be an integral piece manufactured using additivemanufacturing or three-dimensional (3D) printing techniques. The topsheet 102, the bottom sheet 104, the body 106, and the interlockingfeature 108 may include a composite material resulting in a non-textilefloor covering, for example. In yet further examples, the floor panel100 includes an integral, single piece construction of multi-materiallayers, where a material used for the bottom sheet 104 differs from amaterial used for the top sheet 102. The floor panel 100 can bemanufactured to have a specific pattern embossed thereon to match aspecific location in the aircraft (e.g., around doors/galleys).

FIG. 3 is a bottom view of the floor panel 100 showing another partialcross-section, according to an example. In FIG. 3, the bottom sheet 104is not shown, and thus, the plurality of cells 112 of the body 106 areshown. The plurality of cells 112 are each internal to the body 106, anda respective cavity is defined between the top sheet 102, the bottomsheet 104, and first and second internal walls 116, 118 of the body 106.The internal walls 116, 118 are oriented perpendicular to each other tocreate the internal cellular structure of the body 106. Many internalwalls are included to create a number of rows and columns of cells, forexample. Further, the first internal walls 116 can be at any suitableorientation to the second internal walls 118 rather than perpendicular.

The plurality of cells 112 of the body 106 each have a cavity (e.g.,shown in FIG. 4 as cavity 114) and can allow the floor panel 100 to belightweight, as compared to floor panels having a solid structure. Usingcomposite materials for the floor panel 100 with the cellular structurecan enable a high weight-to-stiffness ratio in comparison to use ofsolid materials, for example.

FIG. 4 is a transparent view of a portion of the floor panel 100 to showan example of the plurality of cells 112. As shown each cell of theplurality of cells 112 has a volume that defines a cavity, such as thecavity 114 of a particular cell. Holes, such as hole 120, are includedin each cell 112 based on a manufacturing technique and to allow forfurther weight reduction, for example. The plurality of cells 112 caninclude rectangular or square-like structures arranged in rows andcolumns as shown in FIG. 4; however, each cell 112 can have any suitableshape that is configured to enable the body 106 to function as describedherein.

FIG. 5 is a side view of the floor panel 100. The seat 110 is shown moreclearly in FIG. 5 as the interlocking feature 108 abutting the top sheet102 at about a 90° angle. However, the seat 110 can be configured atother angles including greater than a 90° angle or less than a 90° angleto provide alternate interlocking mechanisms, for example. For example,the interlocking feature 108 may include a lip that extends outward fromthe body 106 of the floor panel 100 to engage an adjacent floor panelduring installation.

FIG. 6 is another side view of the floor panel 100. In FIG. 6, a surface122 is positioned on the top sheet 102. The surface 122 may be a gripsurface (e.g., rubber material), a decorative surface (e.g., a patternresembling wood grain embossed in a substrate, or texture of wood grainprinted into a substrate with a rubberized surface on top of theembossed and/or printed substrate for grip surface), and/or any otheraesthetic desired. The surface 122 is a surface on which passengers ofthe aircraft walk, and thus, a non-slip surface is desired.

FIG. 7 is a side view of another example of another floor panel 124. InFIG. 7, the floor panel 124 is substantially the same as the floor panel100 and includes the top sheet 102, the bottom sheet 104, the body 106,the interlocking feature 108, and the seat 110. The floor panel 124 isconfigured such that the interlocking feature 108 fits into acorresponding interlocking feature 108 of the floor panel 100. The floorpanel 100 may be considered to be configured in a male or female format,and the floor panel 124 is considered in the opposite format such thatthe floor panels 100 and 124 interlock to one another.

Within some examples, as shown in FIG. 1, the interlocking feature 108extends along at least a portion of a perimeter of the body 106. Theperimeter includes two opposing sides 111 and 113 and two opposing ends115 and 117 of the floor panel 100. In one example, the interlockingfeature 108 extends along both sides 111 and 113 and both ends 115 and117 of the floor panel 100. In other examples, the interlocking feature108 extends along one of the sides 111 and 113 or both ends 115 and 117of the body 106, but not along the other side 111/113 of the body 106.

FIG. 8 is another top view of an example of the floor panel 100,according to an example implementation. In FIG. 8, the interlockingfeature 108 extends along one entire side 113, but only partially alongan opposing side 111 of the floor panel 100, and then also only alongone end 117 of the floor panel 100. Thus, the floor panel 100 may beconfigured in many different configurations to fit a number of differentfloor covering areas on an aircraft 150 or other passenger vehicle, andthe interlocking feature 108 can be included on one or both sides 111and 113 of the body 106, one or both ends 115 and 117 of the body 106,or any combination of sides and ends of the body 106, for example. Thefloor panel 100 can also be configured in a number of different sizeswith different lengths and widths. In some examples, the floor panel 100may be five feet (1.52 meters) long for a floor covering along a walkwayin an aircraft 150.

FIG. 9 illustrates an example flooring system 130 in an aircraft 150,according to an example implementation. The flooring system 130 includesa first set 132 of floor panels 100 including floor panels 100 attachedor rigidly attached to a structure 134 of the aircraft. Morespecifically, the floor panels 124 of the first set 132 are rigidlyattached to the structure 134 by permanent adhesive, screws, bolts,snap-fit, etc. The flooring system 130 also includes a second set 136 offloor panels 100, and each floor panel 100 of the second set 136 offloor panels has the interlocking feature 108 for slidably engaging anadjacent floor panel 124 (further shown in FIG. 10). The interlockingfeature 108 is configured to enable lateral relative motion to occur andrestrict vertical relative motion between panels 100 of the second set136 of floor panels 100 and a respective adjacent floor panel 124, forexample (described more fully below). The second set 136 of floor panelsare positioned to define a space 138 between the floor panel 100 and therespective adjacent floor panel 124 to enable the lateral relativemotion to occur between panels 100 of the second set of 136 floor panelsand the respective adjacent floor panel 124. Each floor panel 100 of thesecond set 136 of floor panels is positioned to engage at least oneadjacent floor panel 124 of the first set 132 of floor panels.

The first set 132 of floor panels is attached to the structure 134 ofthe aircraft. For example, the first set 132 of floor panels can beattached directly to the structure 134 of the aircraft 150 using screws,bolts, snap-fit, and/or any other suitable mechanical fasteningdevice(s).

Each panel of the first set 132 of floor panels may be configured as thefloor panel 124 shown in FIG. 7, and each panel of the second set 136 offloor panels may be configured as the floor panel 100 shown in FIG. 1.Following, a panel of the second set 136 of floor panels has theinterlocking feature 108 for slidably engaging an adjacent floor panel124, which may be a floor panel of the first set 132 of floor panels, asshown in FIG. 9 (although other installation configurations exist asdescribed below).

In the configuration shown in FIG. 9, the flooring system 130 includesthe first set 132 of floor panels and the second set 136 of floor panelsarranged in alternating rows. Additional configurations of the flooringsystem 130 are possible and are described below (with reference to FIG.14).

FIG. 10 illustrates a magnified view of a portion of the flooring system130, according to an example implementation. As shown in FIG. 10, theinterlocking feature 108 is configured to enable lateral relative motionto occur between panels of the second set 136 of floor panels and arespective adjacent floor panel due to the space 138. The panels 100 and124 may move toward and away from each other such that the width of thespace 138 changes, for example. The interlocking feature 108 is alsoconfigured to restrict vertical relative motion between panels of thesecond set 136 of floor panels and a respective adjacent floor panel dueto the interlocking feature 108 of the panel 100 abutting theinterlocking feature 108 of the panel 124.

Thus, within examples herein, the flooring system 130 can enable thefloor panels 100 of the second set 136 of floor panels to be capable offloating (e.g., free to move with respect to a fixed structure) on theaircraft subfloor (e.g., the structure 134 of the aircraft). The floorpanel 100 has the interlocking feature 108 that fits with an adjacentfloor panel 124 such that the floor panel 100 can float laterally, butthe interlocking feature 108 prevents the floor panel 100 from liftingoff the subfloor, such as the structure 134.

Dynamics and loads applied to the flooring system 130 due to theaircraft 150 being in flight means that the flooring system 130 isconfigured to withstand determined forces (e.g., about three times theweight of the flooring system 130 of applied force pulling up on theflooring system 130 and about nine times the weight of the flooringsystem 130 of applied force pulling forward on the flooring system 130).The flooring system 130 thus can enable compliance with the mechanics ofdynamic loads experienced in the aircraft 150 (e.g., flight loads andthermal contraction at altitude) while maintaining respective floorpanels 100, 124 substantially in place (e.g., movable only within anarea of the space 138) with respect to each other and the structure 134.

By allowing the floor panels 100 to move relative to adjacent floorpanels 124, the flooring system 130 remain substantially in place, buthas components that are allowed to float laterally to reduce stress onthe flooring system 130 caused by mechanics of aircraft operation.

FIG. 11 is a side view of a portion of the flooring system 130 showingthe floor panel 100 interlocked with an adjacent floor panel 124. Thespace 138 is present when the two floor panels are interlocked. Theinterlocking feature 108 of each respective floor panel 100, 124 isconfigured to restrict the vertical relative motion between the floorpanel 100 and the floor panel 124 by preventing the floor panel 100 frommoving in a direction perpendicular to a surface of the floor panel 100,for example. As shown in FIG. 11, the interlocking feature 108 (i.e., alip) of the floor panel 100 abuttingly contacts the interlocking feature108 (i.e., a lip) of the adjacent floor panel 124 at a surface 140.

FIG. 12 is another side view of a portion of the flooring system 130showing the floor panel 100 interlocked with an adjacent floor panel124. In FIG. 12, a sealant 142 is positioned into the space 138. Thesealant 142 may be compressed allowing for the relative lateral motionbetween the floor panel 100 and the floor panel 124. The sealant 142fills all or substantially all of a volume of the space 138 to preventany foreign materials or substance from being lodged into the space 138,and to provide a smooth and uniform exterior surface onto which thesurface 122 can be positioned.

FIG. 13 is another side view of a portion of the flooring system 130showing the floor panel 100 interlocked with an adjacent floor panel124. In FIG. 13, an elastomer insert 144 is positioned into the space138. The elastomer insert 144 may be an extruded rubber piece, forexample. The elastomer insert 144 may be configured in a “P-shape”(i.e., a shape having a relatively linear portion with a substantiallyarcuate portion attached to the relatively linear portion) such that aportion (i.e., the relatively linear portion) of the elastomer insert144 slides underneath the interlocking feature 108 of the floor panel124 and another portion (i.e., the substantially arcuate portion) of theelastomer insert 144 fills or substantially fills the volume of thespace 138. The surface 122 is then positioned onto the floor panels 100and 124 over the elastomer insert 144. Thus, within examples, therelative motion of the floor panels 100 between anchor points (e.g.,locations where the floor panels 124 are attached to the structure 134)of the first set 132 of floor panels is absorbed by joints betweenadjacent panels that can be filled with the sealant 142 (e.g.,rubberized sealant) or the elastomer insert 144.

FIG. 14 illustrates a schematic layout of the flooring system 130 in aportion of an aircraft 150 or other passenger vehicle, according to anexample implementation. In FIG. 14, various areas of the aircraft 150are shown including galley areas and seating areas. FIG. 14 illustratesa specific layout for a specific aircraft design in which the floorpanel 124 is distributed throughout the area in a manner such that allof the floor panels 100 contact and are adjacent to at least one of thefloor panels 124 along at least one side or one end. In this way, thefloor panel 100 abuts at least one floor panel 124 that is rigidlyattached to the structure 134 of the aircraft 150.

In some examples, some floor panels 100 of the second set 136 of floorpanels are positioned to engage both a respective floor panel 124 of thefirst set 132 of floor panels and a respective floor panel 100 of thesecond set 136 of floor panels. This may occur, for example, using aconfiguration of the floor panel 100 shown in FIG. 8 or otherspecifically configured panels with associated interlocking features 108in a male/female format as needed.

In FIG. 14, some of the floor panels 124 of the first set 132 of floorpanels are anchored to the structure 134 of the aircraft 150 at aperimeter area 152 of the aircraft 150. In addition, some of the floorpanels 124 of the first set 132 of floor panels are anchored to thestructure 134 of the aircraft 150 at one or more door interfaces of theaircraft 150. Locations where the floor panels 124 are attached to thestructure 134 can be referred to as “anchor points”. A specificarrangement and location of the floor panels 124 can depend on a designof the aircraft 150.

In addition, within examples and based on a configuration of the floorpanel 100, the second set 136 of floor panels can be positioned todefine the space 138 between the floor panels 100 and the respectiveadjacent floor panels 124 provided along a perimeter of the second set136 of floor panels to enable the relative motion to occur bothlaterally and longitudinally. In addition or alternatively, in otherarrangements, the second set 136 of floor panels can be positioned todefine the space 138 between the floor panels 100 and the respectiveadjacent floor panels 124 provided along one of both sides 111 and 113of the second set 136 of floor panels or both ends 115 and 117 of thesecond set 136 of floor panels to enable the relative motion to occureither laterally and longitudinally. For example, the interlockingfeature 108 of each floor panel 100, 124 is configured to enablerelative longitudinal motion to occur between panels 100 of the secondset 136 of floor panels and the respective adjacent floor panel 124.

Within examples, the space 138 may be in a range of about 0.1 inches(2.54 millimeters) to about 0.2 inches (5.08 millimeters). However, asize of the space 138 can be different from the previously-mentionedrange due to a size of the floor panel being used. Further, during usethe size of the space 138 can vary as the floor panels 100, 124 moverelative to each other.

FIG. 15 shows a flowchart of an example method 200 for installing theflooring system 130 in the aircraft 150, according to an exampleimplementation. Method 200 shown in FIG. 15 presents an example of amethod that could be used with the floor panel 100 and the floor panel124 shown in FIGS. 1-8, and/or the flooring system 130 shown in FIGS.9-14, for example. In some instances, components and/or apparatuses maybe configured to be used in the functions such that the components areactually configured and structured to enable such performance. In otherexamples, components and/or apparatuses may be arranged to be adaptedto, capable of, or suited for performance of the functions. Method 200may include one or more operations, functions, or actions as illustratedby one or more of blocks 202-210. Although the blocks are illustrated ina sequential order, these blocks may also be performed in parallel,and/or in a different order than those described herein. Also, thevarious blocks may be combined into fewer blocks, divided intoadditional blocks, and/or removed based upon the desired implementation.

It should be understood that for this and other processes and methodsdisclosed herein, flowcharts show functionality and operation of onepossible implementation of present examples. Alternative implementationsare included within the scope of the examples of the present disclosurein which functions may be executed out of order from that shown ordiscussed, including substantially concurrent or in reverse order,depending on the functionality involved, as would be understood by thosereasonably skilled in the art.

At block 202, the method 200 includes attaching the first set 132 offloor panels to the structure 134 of the aircraft 150 at locationsdistributed throughout an area of the aircraft 150. For example, thefloor panels 124 of the first set 132 are rigidly attached to thestructure 134 by permanent adhesive, screws, bolts, snap fit, or bondingor being adhered to the structure 134 in a suitable fashion.

At block 204, the method 200 includes positioning the second set 136 offloor panels such that each floor panel of the second set 136 of floorpanels is positioned to engage at least one adjacent floor panel of thefirst set 132 of floor panels. Each floor panel of the second set 136 offloor panels has the interlocking feature 108 that slidably engages anadjacent floor panel. As discussed above, the interlocking feature 108is configured to enable lateral relative motion to occur and restrictvertical relative motion between panels of the second set 136 of floorpanels and a respective adjacent floor panel. The second set 136 offloor panels are positioned to define the space 138 between a respectivefloor panel 100 of the second set 136 of floor panels and the respectiveadjacent floor panel 100/124 to enable the lateral relative motion tooccur between panels of the second set 136 of floor panels and therespective adjacent floor panel.

At block 206, the method can include engaging the floor panels 100 withthe adjacent floor panels 124 by interlocking the interlocking features108 of each respective floor panel so that the interlocking features 108of respective floor panels abut each other.

At block 208, the method 200 includes filling the space 138 with thesealant 142 or the elastomer insert 144.

At block 210, the method 200 can include installing a surface 122 ontothe first set 132 of floor panels and the second set 136 of floorpanels.

FIG. 16 shows a flowchart of additional functions that may be used withor after implementation of the method 200 in FIG. 15. At block 222,additional functions include removing a respective floor panel 100 (orsubset of panels) of the second set 136 of floor panels. In someexamples, removing a subset of panels can include removing all panels ofthe flooring system 130 and replacing the removed panels with new floorpanels for a new flooring system 130 to change a floor of the passengervehicle.

In still further examples, additional functions can include removing arespective floor panel 124 of the first set 132 of floor panels bydetaching the respective floor panel 124 from the structure 134.

At block 224, additional functions include replacing the respectivefloor panel 100 of the second set 136 of floor panels with a new floorpanel. Replacing the respective floor panel 100 can include inserting anew floor panel 100 (or group of panels) into an opening left byremoving the respective floor panel 100 (or subset of panels). Theinsertion of the new floor panel 100 can be made due to the space 138present between respective panels in the flooring system 130, and byengaging respective interlocking features 108 of the new floor panel 100with an existing panel in the flooring system 130.

In still further examples, additional functions can include replacing arespective floor panel 124 of the first set 132 of floor panels with anew floor panel by reattaching the new floor panel to the structure 134.

Example processes illustrated in the flowcharts in FIG. 15 may beperformed or carried out manually by a system integrator, amaintenance/repair/overhaul company, other third party, and/or anoperator (e.g., an airline or other transport company). The exampleprocesses illustrated in the flowcharts in FIG. 15 can enable a reducedinstallation time of flooring panels due to less installation materialsrequired and lack of rigid attachment of each individual floor panel ofthe flooring system 130 to the structure 134 of the aircraft 150.Rather, only panels in the first set 132 of floor panels can be attachedto the structure 134 of the aircraft 150.

The example processes illustrated in the flowcharts in FIG. 15 also canenable increased reliability and repeatability of installation, as wellas improved aesthetics and customer satisfaction. Furthermore, theexample processes illustrated in the flowcharts in FIG. 15 can enableincreased durability and ability to replace individual panels becausethe floor panels are not bonded to each other in a permanent manner.

The installation of a non-textile flooring system 130 in commercialpassenger aircraft or other vehicle, such as in galley areas of apassenger vehicle, can enable customized aesthetic floor coverings incontrast to the use of generic floor mats. In addition, examplesdescribed herein can avoid issues of buckling of floor coverings becausethe floor panels are allowed to move relative to each other. Thus, floorpanels of the flooring system 130 described herein may not telegraph,buckle, or blister because the interlocking feature 108 of the floorpanels 100 will allow relative lateral motion to occur between the floorpanels while ensuring that the floor panels 100 do not lift when anupward load is applied.

Furthermore, within examples, it is possible to replace a single floorpanel if the panel becomes worn, damaged, defective, or otherwiseundesirable for use. For example, because the floor panels may moverelative to each other, a softer non-adhesive sealant can be used thatis not permanent, thereby allowing easy replacement of one or more floorpanels.

In addition, using the flooring system 130 described herein, a thinlaminate layer is not required over the aircraft subfloor. Rather, floorpanels of the flooring system 130 can be directly attached to thestructure 134 of the aircraft 150, within examples.

Unless otherwise indicated, the terms “first”, “second”, etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

By the term “substantially” and/or “about” it is meant that the recitedcharacteristic, parameter, or value need not be achieved exactly, butthat deviations or variations, including for example, tolerances,measurement error, measurement accuracy limitations and other factorsknown to skill in the art, may occur in amounts that do not preclude theeffect the characteristic was intended to provide.

Different examples of the system(s), apparatus(es), and method(s)disclosed herein include a variety of components, features, andfunctionalities. It should be understood that the various examples ofthe system(s), apparatus(es), and method(s) disclosed herein may includeany of the components, features, and functionalities of any of the otherexamples of the system(s), apparatus(es), and method(s) disclosed hereinin any combination, and all of such possibilities are intended to bewithin the scope of the disclosure.

The description of the different advantageous arrangements has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the examples in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageous examplesmay describe different advantages as compared to other advantageousexamples. The example or examples selected are chosen and described inorder to best explain the principles of the examples, the practicalapplication, and to enable others of ordinary skill in the art tounderstand the disclosure for various examples with variousmodifications as are suited to the particular use contemplated.

It is to be understood that the present disclosure is not to be limitedto the specific examples illustrated and that modifications and otherexamples are intended to be included within the scope of the appendedclaims. Moreover, although the foregoing description and the associateddrawings describe examples of the present disclosure in the context ofcertain illustrative combinations of elements and/or functions, itshould be appreciated that different combinations of elements and/orfunctions may be provided by alternative implementations withoutdeparting from the scope of the appended claims.

What is claimed is:
 1. A floor panel for a flooring system in apassenger vehicle, the floor panel comprising: a top sheet; a bottomsheet opposite the top sheet; a body comprising a plurality of cellseach having a cavity therein, the body situated between the top sheetand the bottom sheet; and an interlocking feature that extends outwardfrom the body for slidably engaging an adjacent floor panel, wherein theinterlocking feature is formed via an outward extension of the bottomsheet beyond the top sheet such that the top sheet is raised withrespect to the interlocking feature to create a seat configured forengaging the adjacent floor panel.
 2. The floor panel of claim 1,wherein the plurality of cells are each internal to the body, and arespective cavity is defined between the top sheet, the bottom sheet,and internal walls of the body.
 3. The floor panel of claim 1, whereinthe interlocking feature extends along a perimeter of the body.
 4. Thefloor panel of claim 1, wherein the interlocking feature extends alongone of both sides of the body or both ends of the body.
 5. The floorpanel of claim 1, wherein the top sheet, the bottom sheet, the body, andthe interlocking feature are a single piece construction.
 6. The floorpanel of claim 1, wherein the seat comprises the interlocking featureabutting the top sheet at about a 90° angle.
 7. The floor panel of claim1, further comprising: a grip surface positioned on the top sheet. 8.The floor panel of claim 1, further comprising: a decorative surfacepositioned on the top sheet.
 9. A flooring system in a passengervehicle, the flooring system comprising: a first set of floor panelsincluding panels rigidly attached to a structure of the passengervehicle; and a second set of floor panels, each floor panel of thesecond set of floor panels having an interlocking feature for slidablyengaging an adjacent floor panel, wherein the interlocking feature isconfigured to enable lateral relative motion to occur and restrictvertical relative motion between panels of the second set of floorpanels and a respective adjacent floor panel, wherein the second set offloor panels are positioned to define a space between a respective floorpanel of the second set of floor panels and the respective adjacentfloor panel to enable the lateral relative motion to occur betweenpanels of the second set of floor panels and the respective adjacentfloor panel, and wherein each floor panel of the second set of floorpanels is positioned to engage at least one adjacent floor panel of thefirst set of floor panels.
 10. The flooring system of claim 9, whereinsome floor panels of the second set of floor panels are positioned toengage both a respective panel of the first set of floor panels and arespective floor panel of the second set of floor panels.
 11. Theflooring system of claim 9, wherein the interlocking feature isconfigured to restrict the vertical relative motion between panels ofthe second set of floor panels and the respective adjacent floor panelby preventing the panels of the second set of floor panels from movingin a direction perpendicular to a surface of the panels of the secondset of floor panels.
 12. The flooring system of claim 9, wherein theinterlocking feature is configured to enable relative longitudinalmotion to occur between panels of the second set of floor panels and therespective adjacent floor panel.
 13. The flooring system of claim 9,wherein a respective floor panel of the second set of floor panelscomprises a top sheet, a bottom sheet opposite the top sheet, and a bodysituated between the top sheet and the bottom sheet, and wherein theinterlocking feature comprises a lip that extends outward from the bodyof the respective floor panel, wherein the lip is formed via an outwardextension of the bottom sheet beyond the top sheet such that the topsheet is raised with respect to the lip to create a seat configured forengaging the adjacent floor panel in the first set of floor panels. 14.The flooring system of claim 13, wherein the lip abuttingly contacts alip of the adjacent floor panel.
 15. The flooring system of claim 9,wherein panels of the first set of floor panels are anchored to thestructure of the passenger vehicle at an area perimeter of the passengervehicle.
 16. The flooring system of claim 9, wherein panels of the firstset of floor panels are anchored to the structure of the passengervehicle at one or more door interfaces of the passenger vehicle.
 17. Theflooring system of claim 9, further comprising: a sealant positionedinto the space.
 18. The flooring system of claim 9, further comprising:an elastomer insert positioned into the space.
 19. An aircraftcomprising the flooring system of claim
 9. 20. A method for installing aflooring system in a passenger vehicle, the method comprising: attachinga first set of floor panels to a structure of the passenger vehicle atlocations distributed throughout an area of the passenger vehicle;positioning a second set of floor panels such that each floor panel ofthe second set of floor panels is positioned to engage at least oneadjacent floor panel of the first set of floor panels, wherein eachfloor panel of the second set of floor panels has an interlockingfeature for slidably engaging an adjacent floor panel, wherein theinterlocking feature is configured to enable lateral relative motion tooccur and restrict vertical relative motion between panels of the secondset of floor panels and a respective adjacent floor panel, wherein thesecond set of floor panels are positioned to define a space between arespective floor panel of the second set of floor panels and therespective adjacent floor panel to enable the lateral relative motion tooccur between panels of the second set of floor panels and therespective adjacent floor panel; and filling the space with a sealant oran elastomer insert.
 21. The method of claim 20, further comprising:installing a surface onto the first set of floor panels and the secondset of floor panels, wherein the surface includes at least one of a gripsurface and a decorative surface.
 22. The method of claim 20, furthercomprising: engaging each floor panel of the second set of floor panelswith the at least one adjacent floor panel of the first set of floorpanels by interlocking the interlocking feature of each floor panel ofthe second set of floor panels to an interlocking feature of the atleast one adjacent floor panel so that respective interlocking featuresabut each other.
 23. The method of claim 20, further comprising:removing a respective floor panel of the second set of floor panels. 24.The method of claim 23, further comprising: replacing the respectivefloor panel of the second set of floor panels with a new floor panel byinserting the new floor panel into an opening left by removing therespective floor panel of the second set of floor panels.